Nestable molded articles, and related assemblies and methods

ABSTRACT

A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about −11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

CROSS REFERENCE TO RELATED APPLICATION AND CLAIM TO PRIORITY

This application is based on provisional application Ser. No.60/924,128, filed May 1, 2007, the disclosure of which is incorporatedherein by reference and to which priority is claimed under 35 U.S.C.§119(e).

FIELD OF THE INVENTION

The present invention relates to man-made molded articles containingbead-and-cove molded depressions, and a method of making the man-mademolded articles. More particularly, the man-made molded articles of thepresent invention provide excellent nesting, one article on another, forshipping and storage of the articles without damage. The presentinvention also relates to methods of making, using, and shipping thearticles, and to assemblies, especially doors, comprising the articles.

BACKGROUND OF THE INVENTION

Man-made boards used in the manufacture of articles such as interiorpaneling and exterior siding are often made of fiberboard, e.g.,hardboard; chipboard; oriented strand board-fiberboard composites;particle board; oriented strand board-particle board composites; and thelike. The intended visible major surfaces of these man-made boards arecommonly embossed to provide a desired appearance, such as a pattern orgrain. Commonly, the fiberboards are molded from a planar cellulosic matto provide the desired embossment, and are laminated on or otherwisesecured to a support structure, such as a frame.

Man-made boards are used in the manufacture of various articles,including doors, and more particularly, in the manufacture of doorskins, or door faces, that are secured to opposite major surfaces of adoor frame. The man-made door skins often are manufactured to simulatethe appearance of expensive natural wood “multi-panel” doors. Toaccomplish this simulation, the door skins are provided with contoureddepressions integrally connecting the simulated panels of the door skinto a major surface portion of the door skin. It is the contoureddepressions, and their superior aesthetic qualities in particular,which, when appropriately manufactured, simulate the attractive milledappearance of a natural wood multi-panel door. One type of milledappearance, known as a bead-and-cove profile, is particularly popular.

FIG. 5 depicts in cross section contoured depressions of conventionaldoor skins 100 having identical bead and cove profiles. Bead portion 101generally refers to a convex portion of the exterior (upper in FIG. 5)surface of the contoured depression, whereas the cove portion 102 isrepresented by a concave region of the exterior surface of the contoureddepression. A ledge 103 separates bead portion 102 and cove portion 102from one another.

It has been found that the surfaces of the contoured molded depressionsof conventional door skins 100 as depicted in FIG. 5 are very difficultto paint uniformly due to density differences generated during moldingof the contours, and due to the confinement of the inclined surfaceareas within the relatively small, molded depressions. It has been foundthat variations in thickness of the molded article adversely affectpaintability, causing the painted article to exhibit a non-uniform coat.Also, the contoured surface of the depression is extremely difficult toprovide with embossments representing, for example, a wood grainpattern, because such embossed texture on depression-forming inclinedwalls has a tendency to cause the article to stick to the mold cavity,causing fibers to pull away from the surface of the molded article whenit is removed from the mold cavity.

Articles possessing the profile of FIG. 5 also do not nest well with oneanother. Rather, adjacent stacked articles are characterized by sizablegaps between the articles, unless localized material removal isperformed by post-molding processing. But localized material removal istime consuming and laborious, and generally inconsistent with highthroughput production environments. Further, stacking instability cancause damage to the contoured depression profiles of the stackedarticles, particularly in the exterior decorative surface areas of thelowermost articles. Damage often is the result of abrasive rubbingbetween the stacked articles experienced during shipping and handling.Loss of detail to the highly valued appearance of the contoureddepressions can ruin the simulation of highly skilled millwork, anddevalue the article.

The relatively large gaps between inefficiently stacked skins representdead or wasted space. As a consequence, the number of articles that canbe stably stored or shipped within a given volume of space, e.g., on apallet or a truck bed, is much less than optimal. The wasted spaceraises production costs, particularly in relation to storage andpre-assembled palletized shipment of the stacked skins.

FIG. 6 illustrates the profile of another door skin 105. In FIG. 6 thenon-uniform thickness is created primarily by the variations inthickness of the contoured area, e.g., bead portion 106 and cove portion107, relative to horizontal planar wall 109. Bead and cove portions 106,107 possess small thicknesses than planar wall 109. Because of theirreduced thicknesses, bead and cove portions 106, 107 require a thickerpaint coat than planar wall 109 to achieve a uniform paint appearance.In order to achieve a uniform, consistent paint appearance between thecontoured area and planar wall 109 and simplify painting, the samethickness coat is normally applied to both the contoured area and planarwall 109. As a result, planar wall 109 receives an amount of paint inexcess of that required to achieve paint uniformity at planar wall 109,thereby unnecessarily increasing labor and production costs. Further,the amount of paint applied to the entire exterior surface of skin 105is dictated by the contoured area, e.g., 106 and 107, even though thecontoured area constitutes a minority of the overall surface area of theexterior surface of skin 105. Furthermore, the increased thickness ofplanar wall 109 compared to the contoured area increases material costsand product weight without offsetting benefits.

The above-discussed problems of conventional molded composite articlesare largely overcome by U.S. Pat. No. 5,543,234, the assignee of whichis also the assignee of this patent application. The '234 patentdiscloses articles designed for efficient, essentially damage-freeshipping and storage, while stacking articles one upon another. Thearticles include decorative molded walls characterized by depressionspossessing convex and concave surface portions having inclined planarsurface portions. An example of a depression profile of a skin 110 ofthe '234 patent is shown in FIG. 7. According to an embodiment of the'234 patent, when the articles are stacked on upon another, inclinedplanar surface portions 112, 114 establish multiple seating contactzones in the form of continuous planar interfaces between opposingsurfaces of stacked articles. The multiple seating zones significantlyreduce relative movement and abrasive contact between stacked skins. Itis thereby possible to stack the articles, or skins, with stable nestingwhile preventing side-to-side rocking, surface abrasion, and damage, asotherwise encountered with conventional skins shown in FIG. 5 duringlong-haul shipping. Stacking of the skins depicted in FIG. 7 also can beachieved with relatively small gaps between the stacked skins, therebyreducing the amount of space required to store and ship skins.Additionally, the skins of FIG. 7 possess a substantially uniformdensity, and consequently require a low number of coats to achieve paintcoating uniformity. Reductions in paint and painting labor time lowerproduction costs.

The inclined planar surface portions of the articles disclosed in U.S.Pat. No. 5,543,234 provide an appearance with unique attributes desiredby some consumers. However, other consumers might interpret theappearance of the inclined planar surface portions as manifesting arelatively contemporary architectural style, and therefore lacking ofsome of the historical millwork detail of a “bead and cove” Colonistdesign.

Therefore, it is desirous to combine classical design aesthetics andnestable functional elements in bead and cove molding geometries of amolded article having a substantially uniform density.

SUMMARY OF THE INVENTION

A first aspect of the invention provides a man-made, molded articlehaving an exterior surface and an interior surface, and comprising aprofile including a planar wall and an adjacent integral moldeddepression. The depression includes a contoured wall extendingdownwardly from the planar wall toward a bottom of the depression. Thecontoured wall comprises a bead portion having opposite bead exteriorand interior surface regions, a cove portion having opposite coveexterior and interior surface regions, and a ledge between the beadportion and the cove portion. The molded article is stackable, one aboveanother for transport, with another molded article of identical profilein a nestable relationship in which multiple contact zones are presentbetween the contoured walls of the stacked articles. The contact zonesinclude an arcuately extending contact zone between the bead exteriorand interior surface regions. The depression has a substantially uniformthickness varying by no more than about +1 percent to about −11 percentin relation to a thickness of the planar wall.

A second aspect of the invention provides a door comprising a frame, andfirst and second door skins respectively secured to opposite sides ofthe frame. At least the first door skin has an exterior surface and aninterior surface, and comprises a profile including a planar wall and anadjacent integral molded depression. The depression comprises acontoured wall extending downwardly from the planar wall toward a bottomof the depression. The contoured wall comprises a bead portion havingopposite bead exterior and interior surface regions, a cove portionhaving opposite cove exterior and interior surface regions, and a ledgebetween the bead portion and the cove portion. The first door skin isstackable, one above another for transport, with an identical door skinof identical profile in a nestable relationship in which multiplecontact zones are present between the contoured walls of the stackeddoor skins. The contact zones include an arcuately extending contactzone between the bead exterior and interior surface regions. Thedepression has a substantially uniform thickness varying by no more thanabout +1 percent to about −11 percent in relation to a thickness of theplanar wall.

A third aspect of the invention provides a method of making a man-mademolded article, comprising molding a structurally sound article. Thearticle has exterior and interior surfaces, and comprises a profileincluding a planar wall and an adjacent integral molded depression. Thedepression comprises a contoured wall extending downwardly from theplanar wall toward a bottom of the depression. The contoured wallcomprises a bead portion having opposite bead exterior and interiorsurface regions, a cove portion having opposite cove exterior andinterior surface regions, and a ledge between the bead portion and thecove portion. The molded article is stackable, one above another fortransport, with another article of identical profile in a nestablerelationship in which multiple contact zones are present between thecontoured walls of the stacked articles. The contact zones include anarcuately extending contact zone between the bead exterior and interiorsurfaces. The substantially uniform thickness of the depression variesby no more than about +1 percent to about −11 percent in relation to athickness of the planar wall.

A fourth aspect of the invention provides stacked man-made, moldedarticles comprising first and second molded articles. The first moldedarticle has a first exterior surface and a first interior surface, andcomprises a first profile including a first planar wall and an adjacentintegral molded first depression. The first planar wall has a firstexterior surface region. The first depression comprises a firstcontoured wall extending downwardly from the first planar wall toward afirst bottom of the first depression. The first contoured wall comprisesa first bead portion having opposite first bead exterior and interiorsurface regions, a first cove portion having opposite first coveexterior and interior surface regions, and a first ledge between thefirst bead portion and the first cove portion. The first depression hasa substantially uniform first thickness varying by no more than about +1percent to about −11 percent in relation to a thickness of the firstplanar wall. The second molded article is stacked on the first moldedarticle. The second molded article has a second exterior surface and asecond interior surface and comprises a second profile with a secondplanar wall and an adjacent integral molded second depression. Thesecond planar wall has a second exterior surface region. The seconddepression comprises a second contoured wall extending downwardly fromthe second planar wall toward a second bottom of the second depression.The second contoured wall comprises a second bead portion havingopposite second bead exterior and interior surface regions, a secondcove portion having opposite second cove exterior and interior surfaceregions, and a second ledge between the second bead portion and thesecond cove portion. The second depression has a substantially uniformsecond thickness varying by no more than about +1 percent to about −11percent in relation to a thickness of the second planar wall. The firstexterior surface and the second interior surface share multiple contactzones between the first and second contoured walls, the contact zonesincluding an arcuately extending contact zone between the first beadexterior surface region and the second bead interior surface region.

A fifth aspect of the invention provides a method of stacking man-made,molded articles. The method comprises providing first and secondman-made molded articles. The first molded article has a first exteriorsurface and a first interior surface, and comprises a first profileincluding a first planar wall and an adjacent integral molded firstdepression. The first planar wall has a first exterior surface region.The first depression comprises a first contoured wall extendingdownwardly from the first planar wall toward a first bottom of the firstdepression. The first contoured wall comprises a first bead portionhaving opposite first bead exterior and interior surface regions, afirst cove portion having opposite first cove exterior and interiorsurface regions, and a first ledge between the first bead portion andthe first cove portion. The first depression has a substantially uniformfirst thickness varying by no more than about +1 percent to about −11percent in relation to a thickness of the first planar wall. The secondmolded article having a second exterior surface and a second interiorsurface, and comprises a second profile including a second planar walland an adjacent integral molded second depression, the second planarwall having a second exterior surface region. The second depressioncomprises a second contoured wall extending downwardly from the secondplanar wall toward a bottom of the second depression. The secondcontoured wall comprises a second bead portion having opposite secondbead exterior and interior surface regions, a second cove portion havingopposite second cove exterior and interior surface regions, and a secondledge between the second bead portion and the second cove portion. Thesecond depression has a substantially uniform second thickness varyingby no more than about +1 percent to about −11 percent in relation to athickness of the second planar wall. The second molded article isstacked on the first molded article so that the first exterior surfaceand the second interior surface share multiple contact zones between thefirst and second contoured walls, the contact zones including anarcuately extending contact zone between the first bead exterior surfaceregion and the second bead interior surface region.

Other aspects of the invention will become apparent from theaccompanying drawings and the detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated in and constitute a part ofthe specification. The drawings, together with the general descriptiongiven above and the detailed description of the preferred embodimentsand methods given below, serve to explain the principles of theinvention. In such drawings:

FIG. 1 is a perspective view of a door manufactured to include twolaminated door skins defining the major outer surfaces according to anembodiment of the invention;

FIG. 2 is a partial sectional view of a pair of stacked door skins;

FIG. 3 is a partial sectional view of a door skin;

FIG. 4 is a partial sectional view of three of the stacked door skins ofFIGS. 2 and 3;

FIG. 5 is a partial sectional view of multiple stacked door skinsaccording to a conventional skin profile;

FIG. 6 is a partial sectional view of multiple stacked door skinsaccording to a commercial skin profile;

FIG. 7 is a partial sectional view of multiple stacked door skinsaccording to another conventional skin profile;

FIGS. 8 and 9 are partial side schematic views of an outline of acontoured wall of a door skin according to an embodiment;

FIG. 10 is a partial side schematic view of an outline of a contouredwall of a door skin according to another embodiment;

FIG. 11 is a partial side schematic view of an outline of a contouredwall of a door skin at varying angles of inclination;

FIG. 12 is a partial side schematic view of an outline of a contouredwall of a door skin according to another embodiment; and

FIG. 13 is a partial side schematic view of an outline of a bead portionof a contoured wall of a door skin according to another embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS AND PREFERRED METHODS OFTHE INVENTION

Reference will now be made in detail to the presently preferredembodiments and methods of the invention as illustrated in theaccompanying drawings, in which like reference characters designate likeor corresponding parts throughout the drawings. It should be noted,however, that the invention in its broader aspects is not limited to thespecific details, representative devices and methods, and illustrativeexamples shown and described in this section in connection with thepreferred embodiments and methods. The invention according to itsvarious aspects is particularly pointed out and distinctly claimed inthe attached claims read in view of this specification, and appropriateequivalents.

In the illustrated embodiments, the man-made, molded articles of thepresent invention are molded in the form of a multi-panel door, or, moreparticularly, a thin door skin to be laminated or otherwise adhered to acore, frame or other support substrate, on both major surfaces of thesupport substrate, to simulate a solid door, preferably with anappearance simulating a natural wood door. Although illustrated as aninterior or exterior passage door, it should be understood that the doormay be used in other applications, for example, as cabinet, closet, andfurniture doors. Further, the opposite door skins may be different oridentical, and optionally the door may comprise only one door skin. Itshould be understood, however, that the principles of the presentinvention apply to much more than the manufacture of doors or doorskins. The present invention may find application to any molded man-madecomposite wood article that includes one or more depressions having acontoured decorative surface. Examples of other composite, molded woodarticles that are capable of being manufactured in accordance with theprinciples of the present invention include decorative hardboard;interior and exterior siding; decorative interior wall paneling;structural cores; roofing material; crating structures; wainscot; otherbuilding and construction materials; and the like.

The articles of the following embodiments are preferably formed oforganic cellulosic material, such as cellulosic fibers or cellulosicparticles, and a binder capable of adhesively binding the cellulosicmaterial together into a structurally stable article. The organicfibrous material is preferably relatively small particles of wood, e.g.,pine, that have passed through a sieve. For example, an 80 mesh sievemay be used, although it should be understood that other sizes bothlarger and smaller are considered to be well within the scope of thepresent invention. The present invention, however, is not limited to theuse of pine; rather, it is contemplated that various types of wood fiberincluding but not limited to oak, cherry, maple and combinations of thesame or other woods may be used. It is further contemplated that the useof organic fibrous material may contain a blend of wood particles. It isfurther contemplated that other fibrous organic materials may be usedincluding but not limited to straw, rice husks and knaff. The organicmaterial may contain a mixture of wood and other fibrous organicmaterials.

The cellulosic fibers, whether in the form of refined, fibrillatedfibers, or in the form of discrete particles, can be molded and adheredtogether with natural or synthetic binders to provide aestheticallypleasing contours and texture in exterior, visible surfaces, includingthe millwork-simulating depressions surrounding a panel. The binder maybe selected from, for example, phenol-formaldehyde resin,urea-formaldehyde resin, and mixtures thereof.

High density fiberboard is particularly useful in various embodiments ofthe invention, although other materials such as medium densityfiberboard may be selected. High density fiberboard contains acellulosic fiber content of about 80 to about 97 percent by weight,based on dry weight. The binder typically constitutes about 2 to about15 percent by weight of the dry weight of the article. Additionalingredients may also be included, such as sizing agents.

The articles of the following embodiments can possess very smallthicknesses on the order of about 0.09 to about 0.2 inch, althoughthinner and thicker articles are also contemplated. The articles can beprepared in isolation. Alternatively, the articles can be moldedtogether with an underlying support or core material, such as anoriented strand board, particle board, plywood, wafer board, or athermoplastic or thermosetting plastic core material by molding the faceor skin cellulosic material together with the underlying core material.The following U.S. patents are hereby incorporated by reference asexamples of various different cores, having cellulosic fibers orparticles as a surface layer, that are suitable for molding inaccordance with embodiments of the present invention: Shaner, U.S. Pat.No. 4,361,612; Wentworth U.S. Pat. No. 4,364,984; Greten U.S. Pat. No.3,098,781; Birmingham U.S. Pat. No. 2,343,740; Bryant U.S. Pat. No.3,308,013; Elmendort U.S. Pat. No. 2,831,793; Hunt U.S. Pat. No.4,246,310; and Barnes U.S. Pat. No. 4,610,913. If the thin cellulosicmolded article (e.g., door skin) is molded separately, the article maylater be laminated or otherwise secured to a support structure.

Turning now to the drawings, and initially to FIG. 1, there isillustrated a door, generally designated by reference numeral 10,including a first door skin 11, and an identical second door skin 11A.Skins 11, 11A are secured, e.g., adhesively and/or with fasteners, toopposite major surfaces of an interior support structure 12, such as adoor frame. The outer surfaces of door skins 11, 11A possess aestheticsurface contours in the visible outer surfaces that correspond tocontours essentially identical to contours of a mold cavity (not shown).

Door skins 11 and 11A are formed in accordance with molding procedureswell known in the art. Although not necessarily by limitation, theprocedures usually employ a mold apparatus including upper and lowermold dies. One or both of the mold dies are movable towards and awayfrom the other mold die. In the closed state, opposing surface of themold dies define a mold cavity. The cavity-defining surface of the oneof the mold dies (e.g., upper mold die) is shaped generallycomplementary or as the inverse of the desired shape of exterior surface13 of door skin 11. For example, the mold die may include raised moldportions dimensioned and arranged to correspond to depressions(discussed below) in exterior surface 13 of door skin 11. Thecavity-defining surface of the other mold die (e.g., lower mold die) hasa shape that is generally complementary or the inverse of the desiredshape of the interior surface of door skin 11. Examples of moldingapparatus and procedures that may be practiced in connection withembodiments disclosed herein are disclosed in U.S. Pat. Nos. 7,096,916,6,743,318, and 6,579,483, the disclosures of which are incorporatedherein by reference.

Two relatively thin door skins 11 and 11A may be molded separately andthen secured on opposite major surfaces of support structure 12.Alternatively, support structure 12 can be disposed between two doorskins 11 and 11A, in the mold cavity, to consolidate the upper and lowerlayers that form door skins 11 and 11A under heat and pressure, whilesimultaneously bonding the door skins to support structure 12, in asingle molding step. In this manner, a strong bond between skins 11 and11A and support structure 12 is formed via resin binder included incellulosic layers 11 and 11A surrounding support structure 12, so that aseparate bonding step for securing door skins 11 and 11A to supportstructure 12 is not needed. Support structure 12 can be a cellulosicmaterial, e.g., wood or an oriented stand board or fiberboard; a plasticmaterial, e.g., foamed or solid polymer, e.g., thermoplastic orthermosetting polymer; a composite material; or other materials.

The exemplary door skins, e.g., 11, shown in FIG. 1 are molded tosimulate a multi-panel door surface. The illustrated embodiment shown inFIG. 1 contains six panels 26, 28, 30, 32, 34, and 36. Panels 26, 28,30, 32, 34, and 36 preferably lie in a common plane with one another. Inthe illustrated embodiment, each panel 26, 28, 30, 32, 34, and 36possesses a rectangular perimeter, and optionally may possess a squareperimeter. It should be understood that door skins 11, 11A may containfewer or more panels than shown, including only a single panel. Further,panels 26, 28, 30, 32, 34, and 36 may possess perimeters other than thatof a rectangle, e.g., the perimeters may undertake the shape of otherpolygons, circles, ellipses, etc.

Surrounding each panel 26, 28, 30, 32, 34 and 36 is a respective moldeddepression 14, 16, 18, 20, 22 and 24, each of which has a rectangularplan appearance as depicted in FIG. 1. The shapes of depression 14, 16,18, 20, 22, and 24 and surrounded panels 26, 28, 30, 32, 34, and 36,respectively, preferably conform to one another. Each depression 14, 16,18, 20, 22 and 24 is completely surrounded by a major or main bodyportion. The main body portion of skin 11 of FIG. 1 includes horizontaldoor surface portions 38, 40, 48, and 50, and vertical door portions 42,44, 46, 47, and 49, shown lying in a common plane, and optionally lyingin a common plane with the panels 26, 28, 30, 32, 34, and 36 as well.

Depressions 14, 16, 18, 20, 22, and 24 are molded to establish inclinedwalls having exterior surfaces that, in accordance with preferredembodiments of the present invention, are of substantially constantdensity and thickness. The exterior surfaces of depressions 14, 16, 18,20, 22, and 24 include contours, preferably characterized by abead-and-cove design. The contours extend downwardly and inwardly fromthe main body portion of door skin 11 to a lowermost portion or bottomof depressions 14, 16, 18, 20, 22, and 24. Slanted wall portions extendfrom the bottom of depressions 14, 16, 18, 20, 22, and 24 furtherinwardly and upwardly to panels 26, 28, 30, 32, 34, and 36,respectively. The cross-sections or profiles of depressions 14, 16, 18,20, 22, and 24 of various embodiments of the invention are described inmore detail below. It should be understood that the cross-sectionalprofiles of depressions 14, 16, 18, 20, 22, and 24 are preferablyidentical to one another, but may be different from one another.

As best shown in FIG. 2, door skins 11, 11A are shown disassembled fromsupport structure 12, and stacked one upon the other in a nestedrelationship. Door skins 11, 11A are identical in profile. Referencenumerals are shown in FIG. 2 for door skin 11 only. For the purposes ofdiscussion, corresponding parts and features of door skin 11A will bereferred to herein using like reference numerals, with the suffix “a”.For example, the depression of door skin 11A (corresponding todepression 18 of door skin 11) will be referred to in this detaileddescription as depression 18 a.

For the purpose of discussion, only the left side leg (with reference toFIG. 1) of depression 18 and its adjoining vertical door portion 42 andpanel 30 are illustrated in FIG. 2. The profiles of depression 18 on thetop and bottom and opposite right side legs of panel 30 are identical.Similarly, depressions 14, 16, 20, 22, and 24 may be identical todepression 18.

Depression 18 is molded to include a contoured wall 50 extendingdownwardly from vertical door portion 42 to the bottom of depression 18,and a slanted wall 52 extending from the bottom portion of depression 18to panel 30. The adjoining vertical door portion 42, contoured wall 50,slanted wall 52, and panel 30 preferably are integrally formed andcontiguous with one another as a unitary unit subjected as a unit to amolding procedure.

Contoured wall 50 extends downwardly from planar wall 42 to bottom 80 ofdepression 18. Contoured wall 50 is characterized by a bead-and-coveconfiguration, comprising a bead portion 54 and a cove portion 56. Beadportion 54 has a convex exterior surface region 58 and an oppositeconcave interior surface region 60. Bead exterior surface region 58extends between a first upper end point 62 and a first lower end point64. Cove portion 56 has a concave exterior surface region 66 and anopposite convex interior surface region 68. Cove exterior surface region66 extends between a second upper end point 70 and a second lower endpoint 72.

Contoured wall 50 further includes a ledge 74 interposed between beadportion 54 and cove portion 56. Ledge 74 has an exterior surface region76 interposed between first lower end point 64 and second upper endpoint 70. Exterior surface region 76 of ledge 74 may be parallel,perpendicular, or askew relative to the exterior surface regions ofvertical door portion 42 and panel 30. Although exterior surface region76 of ledge 74 is shown as generally planar, it should be understoodthat exterior surface region 76 may have other shapes, such as arcuateand stepped. Additionally, contoured wall 50 includes a shoulder 78interposed between first upper end point 62 and vertical door portion42. Contoured wall 50 includes an inclined surface region 81, whichfunctions as a contact zone (discussed below).

Multiple seating or contact zones 82, 84, and 86 are established betweencontoured wall 50 of door skin 11 and contoured wall 50 a of skin 11Awhen skins 11, 11A are adjacently stacked on one another in a nestedrelationship. Contact zone 82 is a continuous contact region representedby an arcuately extending contact interface/zone between convex beadexterior surface region 58 a of skin 11A and concave bead interiorsurface region 60 of skin 11. Contact zone 84 is depicted as a pointcontact between cove exterior surface region 66 a of skin 11A and coveinterior surface region 68 of skin 11, although it should be understoodthat contact zone 84 may comprise an arcuate or linear extendinginterface. Contact zone 86 is depicted as a continuous linear contactzone between exterior surface planar region of bottom portion 80 a ofskin 11A and an interior surface planar region of bottom portion 80 ofskin 11. Continuous linear contact zone 86 is formed by respectiveplanar regions of the interior surface region of bottom portion 80 andthe exterior surface region of bottom portion 80 a. Although shown as alinear interface, contact zone 86 alternatively may possess a convex orconcave curvature interface. It should be understood that two, three,four, or more contact zones may be established between contoured wall 50and contoured wall 50 a.

Another contact zone 88 (FIG. 2) between stacked skins 11, 11A isestablished at the interface of the interior surface region of slantedwall 52 and the exterior surface region of slanted wall 52 a. Contactzone 88 is illustrated as a linear contact zone between planar surfaceregions of slanted walls 52, 52 a. It should be understood that contactzone 88 may possess a convex or concave curvature.

The presence of multiple contact zones, e.g., 82, 84, and 86, includingone or more arcuate contact zones 82, along contoured walls 50, 50 a,together with at least one additional contact zone 88 between slantedwalls 52, 52 a establishes an excellent nesting capability betweenadjacent skins 11, 11A. The multiple contact zones, e.g., 82, 84, 86,and 88 cause an interlocking relationship between stacked skins,substantially reducing or eliminating relative movement between skins11, 11A during transport. Consequently, skins 11, 11A are lesssusceptible to abrasive rubbing and damaging impact forces duringstacking, shipping, and handling.

Certain materials, such as high density fiberboard (HDF), are not veryflowable during mold pressing. For example, a HDF material having aspecific gravity of about 1.0 will not allow for more than a 15 percentcaliper or thickness reduction in comparison to flat zones. As a result,differences in caliper (i.e., the distance between opposing mold faces)practiced during molding result not only in thickness differences, butalso in inconsistent and varying densities along the profile of thearticle, i.e., higher densities corresponding to the smaller calipers.Accordingly, it is desirable to maintain the caliper between opposingmold faces relatively uniform over the depression profile so as to avoidwide variations in molded fiberboard density.

FIG. 4 illustrates the nesting, one above another, of multiple doorskins 11, 11A, 11B having substantially uniform thicknesses that vary byno more than +1 percent to −11 percent in relation to the thickness ofplanar wall 42.

Minor Clip Arcs

FIG. 8 depicts a continuous outline of exterior surface region 58 ofbead portion 54, exterior surface region 76 of ledge 74, and exteriorsurface region 66 of cove portion 56. Bead exterior surface region 58and cove exterior surface region 66 are depicted as minor clip arcs.Bead and cove exterior surface regions 58, 66 span less than 90 degrees,and do not extend beyond perpendicular (90 degrees) relative to theplane in which the exterior surface region of planar wall 42 lies. InFIG. 8, perpendicular is represented by line y. Arcs extending beyondperpendicular line y are referred to herein as major clip arc, discussedbelow.

Contoured wall 50 has an angle of inclination α (alpha) measuredbetween, on the one hand, an imaginary line connecting distal ends(i.e., first upper end point 62 and second lower end point 72) of beadexterior surface region 58 and cove exterior surface 66 region, relativeto, on the other hand, a plane p₃ parallel to the exterior surfaceregion of planar wall 42 and extending through second lower end point72. The angle of inclination a for minor clip arc bead and cove portions54, 56 preferably is in the range of about 20 degrees to about 34degrees, optionally within a range of about 28 degrees to about 33degrees, to provide preferred aesthetic features to the bead-and-covedesign while permitting compact stacking. In FIG. 8, the inclinationangle a equals 33 degrees. An angle of inclination that is less thanabout 20 degrees does not cast sufficiently defining highlight shadowscapable of accurately simulating real millwork detail, and thereby maynot fully emphasize the desired bead-and-cove appearance from afar. Onthe other hand, an angle of inclination exceeding about 34 degreesadversely impacts the thickness uniformity of the articles forcontrolling density. The lack of thickness and density uniformitydeleteriously affects the consistency and uniformity of a paint coatingapplied to the article. As a consequence, an article may require extrapaint coats or special paint to achieve a uniform appearance. Further,high thickness and density variability may increase the weight andoverall thickness of the articles. Angles of inclination exceeding about34 degrees also may adversely affect nestability between stackedarticles. Poor nesting increases space requirements for storing andtransporting skins 11, 11A, thereby raising production costs.

Bead exterior surface region 58 is non-variable (fixed) in its convexcurvature. That is, if exterior surface region 58 were continued alongthe same arcuate path beyond first upper end point 62 and first lowerend point 64, the resulting curved line would form an imaginary firstcontinuous circle having an imaginary first center C₁ of uniform radialdistance to any point on the exterior surface region 58. The angle β(beta) subtending the minor clip arc, i.e., the length of exteriorsurface region 58 extending between first upper end point 62 and firstlower end point 64, is preferably in a range of about 39 degrees toabout 59 degrees. Angles less than about 39 degrees do not fully expressthe curvature of the bead, and may be mistaken as a planar segment. Onthe other hand, a span of greater than about 59 degrees for the minorclip arc negates compliance with a minimum offset angle of 32 degrees,discussed below. In FIG. 8, subtending angle β equals 40 degrees.

In order to determine the subtending angle β, it is helpful to treatexterior surface regions 58 and 66 as segments of respective imaginaryfirst and second circles. Center C₁ of an imaginary first circle can bedetermined by taking any three points P₁ P₂, and P₃ on bead exteriorsurface region 58 using known techniques. For example, two lines can beformed through two pairs of the points. A first line “a” passes throughpoints P₁ and P₂. A second line “b” passes through points P₂ and P₃.Center C₁ of the imaginary first circle is the intersection of two linesperpendicular to and passing through the midpoints of the lines P₁P₂ andP₂P₃. Equations for mathematically ascertaining centers C₁ and C₂ arealso well known.

Likewise, subtending angle δ (delta) of cove exterior surface region 66is determined by treating the concave surface of cove exterior surfaceregion 66 as non-variable (fixed). If exterior surface region 66 werecontinued along the same arcuate path beyond second upper end point 70and second lower end point 72, the imaginary line would continue 360degrees to form an imaginary second circle having an imaginary secondcenter C₂ of uniform radial distance to any point on cove exteriorsurface region 66. The angle δ (delta) subtending the minor clip arc,i.e., exterior surface region 66, is preferably in a range of about 39degrees to about 59 degrees. Angles less than about 39 degrees do notfully express the curvature of the cove, and may be mistaken as a planarsegment. On the other had, a span of greater than about 59 degrees forthe minor clip arc negates compliance with a minimum offset angle of 32degrees, discussed below. In the embodiment depicted in FIG. 8, angle δis equal to 40 degrees.

Another preferred feature for improving the nestability of stacked skinsis to characterize bead exterior surface region 58 minor clip arc withan offset angle γ (gamma) in a range of about 32 degrees to about 50degrees. Offset angle γ is measured between an imaginary first radialline r₁ connecting imaginary first center C₁ to first lower end point64, and a plane p₁ parallel to planar wall 42 extending throughimaginary first center C₁. (p₁ and p₃ optionally but not necessarily maybe collinear, as in FIGS. 8 and 9.) Cove exterior surface region 66preferably also is characterized by an offset angle ε (epsilon) in arange of about 32 degrees to about 50 degrees. Offset angle ε ismeasured between an imaginary second radial line r₂ connecting imaginarycenter C₂ to second upper end point 70, and a plane p₂ parallel toplanar wall 42 extending through imaginary second center C₂. In FIG. 8,γ (gamma) and ε (epsilon) are equal to 32 degrees and 34 degrees,respectively. Reducing either of offset angle γ (gamma) or angle ε(epsilon) below 32 degrees adversely affects the nestability of thesubstantially uniform thickness skins. Nestability of skins havingoffset angles less than about 32 degrees can be improved by varying thethickness of the skins, such as by post-molding material removal, toreduce nesting gaps. However, added steps such as post-molding materialremoval increase labor costs and time.

Referring to FIG. 9, another preferred feature relating to bead exteriorsurface region 58 minor clip arc is that it be characterized by a ratioof the length of a first chord d₁ (extending between first upper endpoint 62 and a first lower end point 64) over the length of imaginaryfirst radial line r₁ (connecting imaginary first center C₁ to firstlower end point 64) in a range of about 0.68 to about 0.95, preferablyabout 0.8. Similarly, cove exterior surface region 66 minor clip arc ispreferably characterized by a ratio of the length of a second chord d₂(extending between second upper end point 70 and second lower end point72) over imaginary second radial line r₂ (connecting imaginary secondcenter C₂ to second upper point 70) in a range of about 0.68 to about0.95, e.g., about 0.8. Minor clip arcs having a ratio of greater thanabout 0.95 lose their intended functionality, displaying undesirablecharacteristics such as blisters, brittleness, and cracking. On theother hand, if the ratio is less than about 0.68, the bead or cove losesits visual appearance of an arcuate surface, appearing more as aninclined plane.

FIG. 10 is another embodiment in which subtending angle β of beadexterior surface region 120 is set at 58 degrees, offset angle γ of thebead portion is set at 32 degrees, subtending angle δ of cove exteriorsurface region 122 is set at 40 degrees, and offset angle ε of the coveportion is set at 50 degrees. Unlike the embodiment of FIGS. 8 and 9,planes p₁ and p₃ are not collinear.

Deviating from the above preferred ranges can result in a loss orreduction in uniformity, stackability, and/or intended functionality ofarticles 11, 11A. Generally, when the above preferred ranges are adheredto, highly stackable articles with desirable substantially uniformthicknesses can also be obtained. In the case of an interior or exteriordoor article, standard doors are usually 1 inch, 1⅜ inch, or 1¾ inch.Assuming a minimum dimension of approximately ¼ inch spacing betweenskins 11, 11A, the profile depth of articles preferably will range fromabout ¼ inch to about ¾ inch for door skins 11, 11A.

FIG. 11 illustrates the influence of inclination angle on profile depth,and more particularly how incremental increases in inclination angle aincrease the depth of the depression. The exterior surface profiles ofthree contoured walls A, B, and C having similar bead-and-cove designsare represented in FIG. 11. From the left to right in FIG. 11, the threeexterior surface profiles of contoured walls A, B, and C have angles ofinclination α_(A) of 34 degrees, α_(B) of 28 degrees, and α_(C) of 20degrees, respectively. The depth of surface profiles A, B, and Cincreases with increasing inclination angle α. Selecting an inclinationangle α of less than 20 degrees creates a shallow depth, creating aflattened appearance that deemphasizes the curvature of thebead-and-cove profile. Selecting an inclination angle α of greater than34 degrees creates a large depth that adversely affects paintability anduniformity of the article. Preferably yet optionally, the depth of doorskin 11 articles according to embodiments of the invention is in a rangeof 5/16 inch to 718 inch. FIG. 11 also displays imaginary first centersC_(1A), C_(1B), and C_(1C) and imaginary second centers C_(2A), C_(2B),and C_(2C) of surface profiles A, B, and C, respectively.

Major Clip Arcs

FIG. 12 illustrates an embodiment in which an article, skin 111,includes a bead exterior surface region 158 molded as a major clip arcextending beyond perpendicular relative to the plane in which theexterior surface of planar wall 42 lies. In FIG. 12, perpendicular isrepresented by line y.

The angle of inclination α (alpha), as measured by an imaginary lineconnecting distal ends (i.e., first end point 162 and second lower endpoint 172) of the, relative to an imaginary plane p₃ parallel to theexterior surface of planar wall 42 extending through second lower endpoint 172) is preferably about 34 degrees or less. An angle ofinclination exceeding about 34 degrees adversely impacts the thicknessuniformity of the articles for controlling density. The lack ofsubstantially uniform thickness and density reduces paint coatconsistency and uniformity, and may require extra paint coats or specialpaint to achieve a uniform appearance. Further, high thickness anddensity variability may increase the weight and overall thickness of thearticles. Angles of inclination exceeding about 34 degrees also reducethe nestability of stacked articles. Poor nesting increases spacerequirements for storing and transporting skins, thereby raisingproduction costs.

It is also preferred that the offset angles γ (gamma) and θ (theta) areeach in a range of about 32 degrees to about 50 degrees. Offset angles γand θ may be the same or different from one another. Offset angle γ, asdefined above, is measured between, on the one hand, an imaginary firstradial line r₁ connecting imaginary first center C₁ to end point 164,and, on the other hand, a plane p₁ parallel to planar wall 42 extendingthrough imaginary first center C₁. Offset angle θ is measured between onthe one hand, an imaginary third radial line r₃ connecting imaginaryfirst center C₁ to end point 162, and, on the other hand, the planep_(l). It should be understood that because bead exterior surface 158constitutes a non-variable clip arc, the distances of r₁ and r₃ areequal to one another. Offset angle of less than about 32 degrees impairthe nestability of skins having uniform thicknesses.

In the event that offset angles γ (gamma) and θ (theta) are eachselected at the high end of the range, i.e., about 50 degrees each, themajor clip arc defined by angle β is equal to about 80 degrees. On theother hand, in the event that offset angles γ (gamma) and θ (theta) areeach selected at the low end of the range, i.e., about 32 degrees each,angle β of the major clip arc is equal to about 116 degrees. Angle β maybe any angle between about 80 degrees and about 116 degrees.

Another preferred feature relating to bead exterior surface 158constituting major clip arc, e.g., FIG. 12, is that it be characterizedby a ratio of the length of a first chord d₁ (between first end points162 and 164) over the length of imaginary first radial line r₁, i.e.,d₁/r₁, in a range of about 0.95 to about 1.686. Major clip arcs having aratio of greater than about 1.686 lose their intended functionality,displaying undesirable characteristics such as blisters, brittleness,and cracking.

FIG. 12 also illustrates ledge exterior surface region 176 and coveexterior surface 166 region of skin 11. Cove exterior surface region 166preferably satisfies the ranges described above. Specifically, coveexterior surface region 166 is preferably characterized by a subtendingangle δ (delta) in a range of about 39 degrees to about 59 degrees, andan offset angle s (epsilon) in a range of about 32 degrees to about 50degrees, wherein offset angle ε is measured between an imaginary secondradial line r₂ connecting imaginary center C₂ to second upper end point170, and a plane p₂ parallel to planar wall 42 extending throughimaginary second center C₂. Cove exterior surface region 166 is alsopreferably characterized by a ratio of the length of a second chord d₂(extending between second upper end point 170 and second lower end point172) over imaginary second radial line r₂ (connecting imaginary secondcenter C₂ to second upper point 170), i.e., d₂ 1r₂ in a range of about0.68 to about 0.95, preferably about 0.8. The depth of the exteriorsurface profile of FIG. 12 is 0.3125 inch. Minor clip arcs having aratio d₂/r₂ of greater than about 0.95 lose their intended functionalityof maintaining defined substantially uniform caliper thickness,displaying undesirable characteristics such as blisters, brittleness,and cracking, and forcing a larger nesting gap between stacked skins. Onthe other hand, if the ratio d₂/r₂ is less than about 0.68, the coveloses its visual appearance of an arcuate surface, appearing more as aninclined plane.

Variable Arcs

FIG. 13 illustrates an embodiment of a door skin 11 having a beadportion with a variable major arc, that is, the curvature of the beadportion is not constant. The variable major clip arc of FIG. 13 iscomposed of multiple non-variable arcs, i.e., a non-variable (fixed)first convex exterior surface region 258 extending between points 262and 263, and a non-variable (fixed) second convex exterior surfaceregion 259 extending between points 263 and 264. The first and secondconvex exterior surface regions 258, 259 share a common tangent point263.

First convex exterior surface region 258 is non-variable. If surfaceregion 258 were extended along a constant arcuate path beyond points 262and 263, the resulting curved line would form an imaginary firstcontinuous circle having an imaginary first center C_(1A) of uniformradial distance to any point on the exterior surface region 258.Similarly, if non-variable second convex exterior surface region 259were extended along a constant arcuate path beyond points 263 and 264,the resulting curved line would form an imaginary second continuouscircle having an imaginary second center C_(1B) of uniform radialdistance to any point on the exterior surface region 259.

First convex exterior surface region 258 constitutes a major clip arc.As explained above, major clip arc preferably possesses offset angles γ₁(gamma) and θ (theta) in a range of about 32 degrees to about 50degrees. Offset angles γ and θ may be the same or different from oneanother. Offset angle γ, as defined above, is measured between, on theone hand, an imaginary first radial line r₁ connecting imaginary firstcenter C₁ to end point 263, and, on the other hand, a plane p_(1A)parallel to planar wall 42 extending through imaginary first centerC_(1A). Offset angle θ is measured between on the one hand, an imaginarythird radial line r₃ connecting imaginary first center C_(1A) to endpoint 262, and, on the other hand, the plane p_(1A). Point k representsthe location where end point 262 would be if the angle θ=θ_(k)=32degrees. Reducing offset angles θ or γ below 32 degrees is undesirable,inasmuch as the reduced offset angles impair the ability to stackidentical skins one upon another with small gaps.

Another preferred feature relating to first convex exterior surfaceregion 258 constituting major clip arc is that it be characterized by aratio of the length of a first chord d₁ (between end points 262 and 263)over the length of imaginary radial line r₃ in a range of about 0.95 toabout 1.686. Major clip arcs having a ratio of greater than about 1.686lose their intended functionality, displaying undesirablecharacteristics such as blisters, brittleness, and cracking.

The maximum length of non-variable second convex exterior surface region259 is determined as follows. An imaginary radius r_(i) set at an offsetangle of 32 degrees from plane p_(1A) is drawn extending from centerC_(1A). Next, first convex exterior surface region 258 is extendedbeyond point 263 until intersecting with imaginary radius r_(i). Thisextension beyond point 263 is represented in FIG. 13 by a dashed arcuateline above the reference character d₂. The point of intersection of theextended surface region 258 and radius r_(i) is designated “i.” Theangle between r₂ and r_(i) is designated φ_(i). An angle φ_(j) equal to100 _(i) but on the opposite side of r₂ is measured, and an imaginaryradius r_(j) is set at φ_(j). Imaginary radius r_(j) intersects withfirst convex exterior surface region 258 at point j. A second chord d₂is extended from point j through point i, and extrapolated untilintersecting the imaginary circle in which second convex exteriorsurface region 259 lies. This point of intersection 264 represents thefarthest extent (or maximum length) that second convex exterior surfaceregion 259 may be extended. In FIG. 13, the minimum offset angle γ₂between r₄ (connecting C_(1B) and p_(1B)) is 43 degrees. This minimumoffset angle γ₂ is greater than the minimum offset angle of 32 degreestypically allowed for a minor clip arc.

Articles embodied herein may provide various benefits. The nestabilityof the articles in close relationship to one another, i.e., with smallinterceding gaps, allows the pre-assembled articles to be shipped andstored in larger quantities in a given space. Further, the presence ofmultiple contact points, including one or more extensive contact zones,reduces movement and resulting abrasive contact between adjacentarticles. The highly stabilized nested articles are therefore lesslikely to experience damage during stacking, shipping, and handling.Additionally, providing the articles with a substantially uniformthickness reduces painting requirements and labor required to establisha uniform coating on the articles. The substantially uniform thicknessof the articles also improves the intended fimctionality of thearticles, such as reduced blistering and cracking.

The foregoing detailed description of the certain preferred embodimentsof the invention has been provided for the purpose of explaining theprinciples of the invention and its practical application, therebyenabling others skilled in the art to understand the invention forvarious embodiments and with various modifications as are suited to theparticular use contemplated. This description is not intended to beexhaustive or to limit the invention to the precise embodimentsdisclosed. Modifications and equivalents will be apparent topractitioners skilled in this art and are encompassed within the spiritand scope of the appended claims.

1-38. (canceled)
 39. A door skin, comprising: a door portion; a doorpanel lying in a common plane with the door portion; and a depressiondisposed between the door portion and the door panel so as to surroundthe door panel and be surrounded by the door portion, the depressioncomprising a contoured wall extending downwardly from the door portiontoward a bottom of the depression at an angle of inclination and aslanted wall extending upwardly from the bottom of the depression to thedoor panel, the contoured wall comprising a bead portion having oppositebead exterior and interior surface regions, a cove portion havingopposite cove exterior and interior surface regions, and a ledge betweenthe bead portion and the cove portion, wherein the door skin isstackable for transportation on a second door skin of identical profilein a nestable relationship in which multiple contact zones are presentbetween the contoured walls of the stacked door skins, the contact zonesincluding an arcuately extending contact zone between the bead interiorsurface region of the door skin and the bead exterior surface region ofthe second door skin.
 40. The door skin of claim 39, wherein the angleof inclination is in the range of about 20 degrees to about 34 degrees.41. The door skin of claim 39, wherein the molded depression comprises aprofile depth in a range of 0.3125 inches to 0.875 inches.
 42. The doorskin of claim 39, wherein the slanted wall comprises a linear contactzone.
 43. The door skin of claim 39, wherein the depression has athickness varying by no more than +1 percent to −11 percent in relationto the thickness of the door portion.
 44. The door skin of claim 39,wherein the door skin comprises a cellulosic material.
 45. The door skinof claim 39, wherein the bead portion extends from an upper end point toa lower end point and has a length in the range of about 39 degrees toabout 59 degrees.
 46. The door skin of claim 45, wherein the beadportion has an offset angle in a range of about 32 degrees to about 50degrees.
 47. The door skin of claim 45, wherein the cove portion extendsfrom a second upper end point to a second lower end point and has alength in the range of about 39 degrees to about 59 degrees.
 48. Thedoor skin of claim 47, wherein the cove portion has an offset angle in arange of about 32 degrees to about 50 degrees.
 49. A door, comprising: aframe; and a first door skin and a second door skin attached to theframe, the first and second door skins each comprising a door portion, adoor panel lying in a common plane with the door portion, and adepression disposed between the door portion and the door panel so as tosurround the door panel and be surrounded by the door portion, thedepression comprising a contoured wall extending downwardly from thedoor portion toward a bottom of the depression at an angle ofinclination and a slanted wall extending upwardly from the bottom of thedepression to the door panel, the contoured wall comprising a beadportion having opposite bead exterior and interior surface regions, acove portion having opposite cove exterior and interior surface regions,and a ledge between the bead portion and the cove portion, wherein thefirst and second door skins are stackable for transportation on oneanother in a nestable relationship in which multiple contact zones arepresent between the contoured walls of the stacked first and second doorskins, the contact zones including an arcuately extending contact zonebetween the bead exterior surface region of the first door skin and thebead interior surface region of the second door skin.
 50. The door skinof claim 49, wherein the angle of inclination is in the range of about20 degrees to about 34 degrees.
 51. The door skin of claim 49, whereinthe angle of inclination is in the range of about 28 degrees to about 33degrees.
 52. The door of claim 49, wherein the slanted wall comprises alinear contact zone.
 53. The door of claim 49, wherein the depressionhas a thickness varying by no more than +1 percent to −11 percent inrelation to the thickness of the door portion.
 54. A door skin,comprising: a door portion; a door panel lying in a common plane withthe door portion; and a depression disposed between the door portion andthe door panel so as to surround the door panel and be surrounded by thedoor portion, the depression comprising a contoured wall extendingdownwardly from the door portion toward a bottom of the depression at anangle of inclination and a slanted wall extending upwardly from thebottom of the depression to the door panel, the contoured wallcomprising a bead portion having opposite bead exterior and interiorsurface regions, the bead portion extending from a first upper end pointto a first lower end point having a length in the range of about 39degrees to about 59 degrees, a cove portion having opposite coveexterior and interior surface regions, the cove portion extending from asecond upper end point to a second lower end point and having a lengthin the range of about 39 degrees to about 59 degrees, and a ledgebetween the bead portion and the cove portion, wherein the door skin isstackable for transportation on another door skin of identical profilein a nestable relationship.
 55. The door skin of claim 54, wherein thebead portion has an offset angle in a range of about 32 degrees to about50 degrees.
 56. The door skin of claim 54, wherein the cove portion hasan offset angle in a range of about 32 degrees to about 50 degrees. 57.The door skin of claim 54, wherein the angle of inclination is in therange of about 20 degrees to about 34 degrees.
 58. The door of claim 49,wherein the depression has a thickness varying by no more than +1percent to −11 percent in relation to the thickness of the door portion.